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University of Jordan
Department of Chemical Engineering
Dr. Ali Al-Shawabkeh
Lecture Notes -11-
Heat Exchangers 5
Types of Shell and Tube Heat Exchangers:
1- Fixed Head (Fixed Tubesheet) STHE:
The tubesheet is welded to the shell.
The fixed tubesheet STHE has two tubesheets.
Used for relatively limited temperature range service.
A shell expansion joint is
provided to allow for the tube
expansion. Expansion joints
(built-in joints) also allow for
shell expansion.
The end covers are removable
so that the inside of the tubes
can be cleaned by rodding or
other similar tools. This type of
cleaning is usually carried out
in situ so some space should be
allowed in the piping layout to allow for this.
Due to inspection and cleaning difficulties, fixed STHE are used where shell-side
fouling is limited.
The shell-side must be chemically cleaned since the tube bundle cannot be removed
from the shell.
2- U-Tube (U-Bend) STHE:
The U-tube STHE has only
one tubesheet.
Used when fouling of the
tubes on the inside is
unlikely (the bend in the
tubes inhibits the cleaning
and inspecting the inside of
the tubes).
A baffled channel is bolted
between the tubesheet and
the channel cover.
By unbolting the channel
from the shell, the tubesheet
and the bundle can be removed from the shell so that the outside of the tubes can be
cleaned.
2 c
T
joint
Expansion
STHE tubesheet Fixed
STHE tube - U
Bonnet
cover
Channel
Channel
baffle
Channel
Shell
Tubesheet
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Because the tube bundle is fastened to only one tubesheet, the tubes are free to
expand.
Can be used
where the
temperature
difference
between
shell-side and
tube-side
fluids is quite
large.
The channel
baffle
(partition)
dividing the
channel
directs
incoming
tube-side
fluid through
only half of
the tube
openings.
3- Floating Head STHE:
Are used when the media being handled causes fairly rapid fouling, and the
temperature creates expansion problems (tubes can expand freely).
One of its two tubesheets is bolted between the shell and the channel in a fixed
position.
a) Pull through type:
The other
(floating)
tubesheet
together with
its cover
floats inside
the shell
(free to move
horizontally).
Because the
tube bundle
and floating
head can
move
horizontally,
the tubes are free to expand and contract.
STHE tube - U
chamber
Lower
chamber
Upper
STHE head floating through - Pull
Tubesheet
Cover
head Floating
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By unbolting the channel flange and the stationary tubesheet, the tube bundle and the
floating head can be withdrawn as a unit (this permits cleaning and inspection of the
outside of the tubes).
To inspect and clean the tubesheet and tubes inside, the channel cover, shell cover,
and floating head cover should be removed.
b) Split backing-ring type:
The diameter of the shell cover is greater than the diameter of the rest of the shell
holding the tubes.
The tubes, the tubesheet and the floating head cover cannot be pulled through as one
unit.
The tube bundle can be pulled, if the floating head cover, shell cover, and the split
ring are first removed.
The clearance between the tube bundle and shell of the pull-through type is greater
than that of the split-ring type.
Therefore, the split backing-ring STHE is more efficient than the pull-through one.
The split backing-ring STHE, however, has more parts. Thus, it is more expensive
than the pull-through one.
bundle Tube
head Floating
cover Shell
cover
head
Floating
Clearance
STHE
head floating
through - Pull
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The split backing-ring STHE is also harder to disassemble. First, the shell cover is
unbolted from the shell. Then the floating head cover and split backing-ring are
unbolted from the floating tubesheet. Then, the channel is unbolted from the other end
of the shell. And finally, the tube bundle is pulled from the channel end.
Since disassembly is more time-consuming, the split backing-ring STHE is more
costly than the pull-through one.
Cleaning and Maintenance of Shell and Tube Heat Exchangers:
If a fouling problem has been neglected for some time, mechanical cleaning such as
cutting or scraping, maybe necessary.
The heat exchanger must be dismantled (disassembled) for mechanical cleaning
(usually after some time of operation).
Many deposits can be removed without shutting down the heat exchanger. Cleaning
while the exchanger is operating is called on-line maintenance.
head Floating
cover Shell
STHE head
floating ring
backing - Split
Cover
ring Split
tubesheet Floating
Shell
Channel
Clearance
43 42 1 43 42 1
STHE
through - pull
STHE ring
backing - split
Clearance Clearance
STHE through - Pull
STHE ring - backing Split
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In a typical method used for online-maintenance, chemicals are added to the fluids
flowing through the shell-side or tube-side.
It is not necessary to dismantle the
exchanger for chemical cleaning.
Cleaning of the outside or inside of
the tubes maybe done by spraying
pressurized water (using a water
jet). This cleaning method is called
hydroblasting.
The force of the water loosens the
deposits and washes them away.
Steam jets are also used to clean
heavy hydrocarbon deposits (the
heat generated by the steam softens
the deposits and they are then
washed away by the steam
pressure).
For the most difficult deposits which resist chemicals or hydroblasting, mechanical
methods are used.
Testing for Leaks:
If the two fluids in the HEx have different physical properties (like water and oil) it is
usually easy to tell them a part.
The easiest way to test
for leaks is to take a
sample from the lower
pressure fluid.
If the fluids are water
and oil, for example,
then it is easy to see if
there is a leak by just
looking at the sample.
If the fluids are very
similar, a chemical test
may be necessary.
If visual or chemical
tests do not indicate a
leak, further testing
maybe necessary. These
further tests are called hydrostatic tests, because they usually involve using water
under high pressure.
In the case of tube-side test, the shell-side fluid is drained, and a drain point, such as a
disconnected lower nozzle or bleeder valve, is left open. The tube-side fluid is
replaced with water under high pressure which fills the tube bundle. If there are leaks
in the tubes or at the tube ends, the pressurized water in the tube bundle will be forced
Hydroblasting
(water jet)
tubes leaking
for ends Observe
pressure
under
Water
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through the leak points into the shell. Such fluid will accumulate in the bottom of the
shell and eventually run out the drain
points where it can be observed by the
operator.
The same kind of test can be made on the
shell-side of the exchanger. In that case, the
tube-side of the HEx is drained of fluid,
and a tube-side drain point is left open. The
shell is filled with water under pressure.
Fluid running from the tube-side drain
point will indicate a leak in the tube
bundle.
In the case of a fixed tubesheet HEx, the
end plates or bonnet covers are removed. It
is then possible to directly observe the tubesheets and tube ends. The shell is filled
with water under pressure. The
pressurized fluid enters any
leaking tube at the point where the
tube leaks. This fluid accumulates
in the tube and runs out of the tube
end. By observing the tubesheet, it
is possible to tell which tube is
leaking.
To test a partially dismantled
floating head HEx, the shell cover
is removed, and the tube bundle is
filled with water under pressure.
The leak can be observed if it is located in the floating head gasket or in the tube ends
at the floating head. If the leak is located in the tube walls farther back in the
exchanger or at the tube ends in the
stationary head, fluid will be
observed in the shell. The operator,
however, will not be able to locate
the source of such leaks because the
tube bundle and stationary head are
not visible.
If the leak is coming from one end of
these areas, a different test is
necessary. The channel cover is
removed and tube side fluid is
drained. The shell is filled with water
under pressure. Fluid will enter the tubes at the points where they leak, accumulate in
the tubes, and run out the tube ends. By observing the tubesheet, the operator can tell
which tube is leaking.
Normal test pressure is usually 1.5 times the designed operating pressure.

tube
Loose
A tube which
has come loose
in the tubesheet
head
Floating
pressure
under Water
Shell
leakes Observe
pressure
under Water
end head
Floating
leakes Observe
cover Channel
ring test
or Cover